Protective coating compositions

ABSTRACT

Described are polymer compositions that include lattices (e.g., polymer emulsions or suspensions in an aqueous phase) and that contain a gloss reducing agent and that are useful in various finish compositions such as in floor care compositions.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. provisional appl. No.61/226,114 filed Jul. 16, 2009, the entire disclosure of which isincorporated herein.

BACKGROUND INFORMATION

Polymeric coatings are used to coat and protect a variety of surfaces inapplications including paints, wood finishing, printing, photography,floor care products, waxes, polishes, etc. A polymer composition can bein the form of one or more solid polymer ingredients dispersed orsuspended in a liquid medium, e.g., water, organic solvent, andcombinations or blends of organic solvent with water. The polymercomposition can be combined with other functional ingredients such assurfactants, catalysts, and gloss control agents to produce usefulderivative compositions such as, e.g., a finish composition. A polymercomposition or finish composition can be applied to a surface andallowed to dry or cure, to produce a protective coating.

Relative gloss of a dried or cured finish composition can be a veryimportant property of certain compositions, particularly paints, floorcare products, coatings used in printing and photography, wood finishes,and the like. Different levels of sheen (from glossy to matte) arenecessary for a variety of applications and tastes. These levels rangefrom high gloss, semi-gloss, eggshell, flat, matte, and the like.

Conventional measures for reducing gloss include adding any of variousgloss control (reducing) agents to a polymeric coating composition.Examples include solid particulate materials such as silica,matte-producing wax emulsions, and high-acid functional polymerthickeners.

Polymeric floor care products, sometimes referred to as polish, finish,or wax, often are used to protect and enhance appearances of floors madeof wood, synthetic resins, concrete, marble, terrazzo, stone, and thelike. These products require periodic application of liquid polymericfloor care compositions, which dry to a protective finish. Theprotective finish can exhibit properties such as resistance toscratching and scuffing, resistance to marking from shoes, and the like,along with a selected sheen (high gloss, gloss, flat, matte, etc.). Thefloor care composition is applied to a floor surface and allowed to forma film (coalesce) as the carrying solvent evaporates. Film formationdesirably can occur at room temperature and the resulting film desirablycan be burnished or removed if damaged or compromised.

In floor polish compositions, one or more film-forming polymers aredissolved, dispersed, or suspended in a liquid medium. Although organicsolvents can be used, water is the liquid medium of choice in manycurrently commercial polymer compositions. Because many polymers areinsoluble in water, aqueous floor polish compositions also requiresurfactant to keep the polymer particles dispersed or suspended in thecontinuous aqueous phase. Other common ingredients include one or morecrosslinking agents (preferably one that can reversibly crosslink thepolymer chains from which the protective film is formed), one or morematerials designed to aid in the flow, wetting, or leveling of thecomposition across the floor surface, one or more coalescents,plasticizers, and waxes.

Many different types of polymers have been used to make floor polishcompositions. Commercial polishes typically include styrene-acrylicinterpolymers, i.e., polymers that include mer derived from one or moreacrylic-type monomers and styrene mer. Floor polishes based on astyrene-butadiene interpolymers recently have become available.

That which remains desirable is a gloss reducing agent that can be usedwith a variety of polymers in finish compositions.

SUMMARY

Briefly, the described invention involves polymer materials andcompositions that include polymer and a metal salt of a fatty acid as agloss control (e.g., gloss reducing) agent. These include polymercompositions and their derivatives, such as various types of finishcompositions. A polymer-containing composition can be a liquidsuspension, dispersion, water-based, solvent-based, or any other formuseful to produce a dried or cured (i.e., “dried”) polymer coating on asurface; examples include floor care compositions, paints, woodfinishes, waxes, polishes, etc., for application to and protection ofsurfaces including floors, walls, furniture, or other vertical orhorizontal surfaces. The polymer compositions and derivative finishcompositions can exhibit useful or advantageous stability, film-formingproperties, and other physical properties, and dried coatings of apolymer composition or a finish composition can exhibit a selected glosslevel based on varying amounts or types of ingredients including themetal salt of a fatty acid. An exemplary metal salt of a fatty acid iscalcium stearate.

In one aspect is provided a polymer composition that includes polymer,organic or aqueous liquid, and metal salt of a fatty acid. Thecomposition includes from 0.5 to 10 parts by weight (pbw) metal salt ofa fatty acid and from 10 to 45 pbw polymer. The polymer composition canbe in the form of a finish composition.

The finish composition can be in dried form and, when thus provided, canexhibit a gloss reading, when measured according to ASTM D-1455-87, ofbelow 50.

In another aspect is provided a method of providing a polymercomposition. To a polymer in a liquid medium is added a metal salt of afatty acid in an amount to reduce gloss of the polymer composition upondrying.

Still further aspects involve methods of providing the foregoing coatedfloor and of providing the composition.

Other aspects of the present invention will be apparent to theordinarily skilled artisan from the description that follows. To assistin understanding that description, certain definitions are providedimmediately below, and these are intended to apply throughout unless thesurrounding text explicitly indicates a contrary intention:

-   -   “polymer” means the polymerization product of one or more        monomers and is inclusive of homo-, co-, ter-, tetra-polymers,        etc.;    -   “mer” or “mer unit” means that portion of a polymer derived from        a single reactant molecule (e.g., ethylene mer has the general        formula —CH₂CH₂—);    -   “copolymer” means a polymer that includes mer units derived from        two reactants, typically monomers, and is inclusive of random,        block, segmented, graft, etc., copolymers;    -   “interpolymer” means a polymer that includes mer units derived        from at least two reactants, typically monomers, and is        inclusive of copolymers, terpolymers, tetrapolymers, and the        like;    -   “polyene” means a molecule with at least two double bonds        located in the longest portion or chain thereof, and        specifically is inclusive of dienes, trienes, and the like;    -   “polydiene” means a polymer that includes mer units from one or        more dienes;    -   “polymer composition” means a composition that includes at least        one type of polymer and at least one metal salt of a fatty acid;    -   “additional ingredient” means any one or more additives,        adjuvants or other compounds or complexes added to a polymer        composition to produce or provide a desired physical property or        effect (e.g., a film formation, leveling, chemical or mechanical        stability, chemical reactivity upon cure or drying,        compatibility between ingredients, viscosity modification,        color, or another aesthetic property) that otherwise would not        present, or present to a different degree, in a polymer        composition;    -   “finish composition” means a polymer composition to which has        been added one or more additional ingredients so to provide        composition having a specific utility such as, e.g., a paint,        wax, polish, floor care composition, wood finish, or other        coating product;    -   “external surfactant” means a surface active agent that is        separately added directly to a composition and is not present as        a result of being a component of another ingredient of the        composition;    -   “internal surfactant” means a surface active agent that is used        in the preparation of a polymer; and    -   “gloss” means the intensity of specularly reflected light, a        measurement which acts as an indicator of the relative roughness        of the reflecting surface.

All values herein in the form of percentages are weight percentagesunless the surrounding text explicitly indicates a contrary intention,and all descriptions of minimum and maximum values for a given propertyfurther include ranges formed from all combinations of individualminimum and individual maximum values.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The described invention involves polymer-containing compositionsreferred to as polymer compositions and finish compositions, each ofwhich contain polymer and a metal salt of a fatty acid as a glosscontrol agent. A polymer-containing composition can contain solids inthe form of polymer and metal salt of a fatty acid, these ingredientsbeing dissolved, dispersed, suspended, or otherwise contained in aliquid medium. The liquid medium may be water, an organic solvent, or acombination of water and organic solvent, and can preferably an aqueousmedium that contains mostly or entirely water.

Exemplary polymer compositions contain solid ingredients that consist ofor consist essentially of polymer and metal salt of a fatty acid,suspended, dissolved, or dispersed in a liquid medium that is organic oraqueous. Preferred liquid media include water or a blend of water andorganic solvent that is at least 50 weight percent water (based on totalweight of the liquid medium), often more than 80 weight percent water,and typically more than 90 or 95 weight percent water.

For a composition that “consists of” polymer and metal salt of a fattyacid, the solids can include synthetic polymer(s) as described hereinand metal salt of a fatty acid, as well as small amounts of otheringredients used to prepare the polymer or the metal salt of a fattyacid. Such ingredients can include non polymer byproducts of thepolymerization reaction; solid ingredients useful or appurtenant topreparation of the polymer such as chain transfer agent (e.g., up to ˜3weight percent based on total weight of monomers), internal surfactant,commonly used at up to ˜5 weight percent surfactant based on the amountof polymer, catalyst, plasticizer, coalescing agent, internalcrosslinking agent (e.g., used at up to ˜3 weight percent), and anyother polymerization or processing aids, if used; and unused monomer orother reactant(s). Examples of non-monomer ingredients used to prepare apolymer are described in more detail below.

Solids that consist essentially of polymer and metal salt of a fattyacid also can include the foregoing ingredients as well as small amountsof other ingredients such as any non-polymer byproducts of apolymerization reaction (low molecular weight reaction products) orunused reactants (monomer, internal crosslinking agent, etc.); any othersolid ingredient useful or appurtenant to preparation of the polymersuch as chain transfer agent, surfactant (commonly used at up to ˜5weight percent surfactant based on the amount of polymer), catalyst,plasticizer, coalescing agent, other polymerization or processing aids,if used; and can also be considered to include up to ˜5 weight percentof other solid ingredients (based on total weight solids of the polymercomposition), e.g., up to 3 weight percent other solid ingredients,preferably less than 2 or 1 weight percent other solid ingredients basedon the total amount (weight) of the solids in the polymer composition.These “other” ingredients can be any ingredient used to improve apolymer composition or to prepare a finish composition, many general andspecific examples of which are described herein.

Certain preferred polymer compositions can be aqueous emulsions ordispersions that include particles of polymer entrained throughout acontinuous aqueous phase, and also containing metal salt of a fatty acidsuch as calcium stearate. The total amount of solids (e.g., total solidsby weight) in a polymer composition can vary widely including, forexample, from 30 to 60 weight percent total solids, from 35 to 55 weightpercent total solids, or from 38 to 45 weight percent total solids,based on the total weight of the polymer composition.

As part of the total solids, a polymer composition can contain anydesired or useful amount of polymer solids, e.g., relative to totalsolids of a polymer composition. Exemplary amounts of polymer solidsrelative to total solids in a polymer composition can be an amount ofpolymer in the range from 70 to 98 weight percent polymer per totalweight solids of a polymer composition, commonly from 75 to 98 weightpercent polymer per total weight solids. The remaining solids can bemade up of other useful solid materials such as metal salt of a fattyacid or materials used in or remaining from a process of producingpolymer. (In this context, and unless specifically indicated otherwiseherein, weight percent polymer refers to only polymer material and notto solid materials used to prepare the polymer or solid materials thatare byproducts of a polymerization reaction, if present).

Polymer compositions and finish compositions derived therefrom cancontain any useful amounts of polymer and metal salt of a fatty acid,e.g., amounts that result in one or more desired utility, stability,compatibility, etc., of a polymer composition or a derivative finishcomposition, including desired gloss properties. Preferred amounts ofpolymer to metal salt of a fatty acid in a polymer composition can be upto 10 pbw metal salt of a fatty acid per from 10 to 45 pbw polymer,e.g., from 2 to 6 pbw metal salt of a fatty acid per 12 to 40 pbwpolymer. These amounts can apply to the relative amounts of these twoingredients in both a polymer composition and in any type of finishcomposition, unless additional amounts of polymer or metal salt of afatty acid are added to the polymer composition to produce the finishcomposition. (In this context, parts by weight polymer refers only topolymer material and not to materials used to prepare the polymer ormaterials that are byproducts of a polymerization reaction, if present).

Non-limiting examples of useful polymers include any of a variety ofpoly-acrylates, styrene-polydiene polymers, polyurethanes (e.g., aqueouspolyurethane resin comprising polyurethane polymer that includes abonded carboxylic acid or carboxylate group), and the like, or otherwiseuseful in preparing finish compositions such as paints, floor carecompositions, wood finishes, waxes, polishes, etc.

Metal salts of a fatty acid include chemical compounds that include ahydrocarbon (i.e., monovalent hydrocarbyl) chain, a carboxylic acid, andan associated metal ion. Their general formula is M^(+x)[O⁻(C═O)R]_(x),where M is a metal that may be mono- or multivalent, i.e., x can be aninteger such as 1, 2, or 3; examples of metal atoms designated M includeCa, Al, Mg, and others such as Zn, Ba, Zr, Ni, Fe, Cd, Sr, Bi, Be, Co,Pb, Cu, Ti, Sb, etc.), with Ca⁺² being a preferred metal ion.Optionally, mixtures of two or more different metals can be includedwith metal salts of one or more fatty acid, in a composition asdescribed. In the formula, R can be a hydrocarbyl group that can be astraight, branched, and optionally saturated or unsaturated monovalentC₅-C₂₅ hydrocarbon chain, e.g., C₁₅-C₂₀ in length; examples ofcorresponding acids include stearic acid, oleic acid, linoleic acid,palmitic acid, arachidic acid, combinations of these, and others.Optionally, mixtures of two or more different hydrocarbyl groups can beincluded with metal salts of fatty acids, in a composition as described.

A particularly preferred M for purposes of affecting gloss of a driedpolymer composition or a finish composition, is calcium, commonly foundas calcium ion, Ca²⁺. A particularly preferred hydrocarbyl chain of ametal salt of a fatty acid for use in a polymer composition or finishcomposition as described herein, e.g., a floor care composition, toaffect gloss of a dried polymer composition or a dried finishcomposition, is a saturated C₁₈ hydrocarbyl stearate chain derived fromthe stearate anion of stearic acid (C₁₇H₃₅COO⁻). A particularlypreferred metal salt of fatty acid for use in a polymer composition asdescribed herein, to affect gloss of a dried polymer composition or adried finish composition, is calcium stearate, also known as calciumoctadecanoate (Ca(C₁₈H₃₅O₂)₂).

The metal salt of a fatty acid can constitute any portion of a polymercomposition or finish composition that results in gloss control. Themetal salt of a fatty acid normally can be added to a polymercomposition after reaction of monomers to form polymeric chains, sometal salt of a fatty acid normally is not incorporated into polymer asa mer unit, or as crosslinking agent, or by mechanical associationwithin polymer particle. Upon addition to a polymer composition (e.g.,latex), the metal salt of a fatty acid may become dissolved, suspended,or dispersed, in a liquid medium of the polymer composition such as acontinuous liquid phase. If suspended or dispersed as particles in acontinuous liquid phase, the particles can be of any size (designated asan average or mean of particle diameter) useful to produce a desiredgloss reducing or matting effect, e.g., less than 300 nm mean diameter,from 50 to 200 nm mean diameter, or from 100 to 180 nm mean diameter.

Exemplary finish compositions include floor care compositions, waxes,polishes, wood finish products, photographic and printing coatings,paints, glass (window or lens) coatings, and the like. A finishcomposition can include amounts of polymer and other solids that can beuseful in any one or more of these, or other, coating applications.

Finish compositions can be emulsions or dispersions that includediscontinuous particles of polymer dispersed or suspended in acontinuous liquid phase, metal salt of a fatty acid such as calciumstearate, and added ingredients desired in a finish composition. Therelative amounts of liquid medium of a continuous liquid phase to solids(polymer, metal salt of a fatty acid, and other solid ingredients) in afinish composition, can be any useful amounts, for example an amount ofliquid medium (e.g., water, organic solvent, or a blend of these) toproduce a composition that includes from 5 to 40 weight percent totalsolids, from 10 to 30 weight percent total solids, or from 12 to 25weight percent total solids (per total weight finish composition).

A finish composition provided by blending one or more additionalingredients into a polymer composition can include solids present fromthe starting polymer composition and additional solids from theadditional ingredients. (The amounts and types of solids in the polymercomposition can be as described herein.) Exemplary amounts of solids incertain embodiments of finish compositions that are present due to theirpresence in a starting polymer composition to which one or moreadditional ingredients are added (this includes polymer solids, metalsalt of fatty acid, and any other solids present in a polymercomposition as described herein), relative to a total amount solids in afinish composition, can be an amount of solids in the range from 70 to92 weight percent solids present as a portion of the polymercomposition, per total weight solids of a finish composition, e.g., from80 to 90 weight percent solids present as a portion of the polymercomposition per total weight solids in a finish composition. In certainembodiments, the remaining 8 to 30 or 10 to 20 weight percent solids canbe made up of solid materials, e.g., additional ingredients, added tothe polymer composition to produce the finish composition as describedherein, including amounts of surfactant, defoamer, leveling agent, etc.,as described and as otherwise known in the polymer and finishcomposition arts, as desired and useful.

Examples of additional ingredients include surfactants, pigments,wax(es), leveling agents, stabilizers, preservatives, etc. Specificexamples of useful ingredients used to produce a finish compositioninclude crosslinkers, catalysts, surfactants (any type), antifoamagents, waxes, pigments, plasticizers, coalescents, leveling agents,antimicrobial agents or other preservatives, and even additional glosscontrol agents if desired.

In alternate embodiments, other relative amounts of solid materialsadded to a polymer composition as “added ingredients,” per total solids,can be useful, such as when a relatively larger amount of wax,alkali-soluble resin, or polyurethane polymer, is added to a polymercomposition.

Relative amounts of polymer solids and metal salt of a fatty acid in afinish composition can be the same as those present in the polymercomposition from which a finish composition is prepared. For instance,if additional ingredients do not include additional metal salt of fattyacid or polymer solids, the relative amounts of these two ingredients ina finish composition will be the same as their relative amounts in thepolymer composition.

In alternate embodiments of finish compositions and their methods ofpreparation, in addition to additional ingredients discussed directlyabove, metal salt of a fatty acid can be added to a polymer compositionas an additional ingredient to further modify gloss of a derivativecoating of the finish composition. A polymer composition can beprepared, e.g., for sale or use, to include a specified level of metalsalt of fatty acid on any given basis, such as an amount relative to theweight of polymer solids in the polymer composition, an amount of atotal weight of polymer composition (of which the metal salt of a fattyacid is a component), an amount of a total weight of all solids in apolymer composition, etc. According to embodiments of compositions andmethods of the described invention, additional ingredients blended withthe polymer composition, containing a known amount of metal salt offatty acid, optionally can include an additional amount of metal salt offatty acid, e.g., to alter or tailor (e.g., reduce) the gloss level ofthe dried finish composition. The amount can be such that, when added tothe amount in the polymer composition, will result in a desired level ofgloss of a dried finish composition.

An example of a finish composition is a floor care composition, whichcan include useful amounts of polymer and metal salt of a fatty acid, asdescribed above, and further may contain any one or more addedingredients including surfactant (which may be any of various knowntypes including anionic, ionic, nonionic, etc.), plasticizer, wax,defoamer, preservative, combinations of these, or other addedingredients.

A typical floor care composition can be characterized as a suspension ordispersion of solid particles, including polymer(s) in a liquid medium,preferably a continuous aqueous phase that includes a large amount ofwater, a majority of water, or preferably entirely water. Exemplarydescriptions of such compositions and their production can be found inU.S. Pat. Nos. 3,328,325, 3,467,610, 3,554,790, 3,573,329, 3,711,436,3,808,036, 4,150,005, 4,517,330, 5,149,745, 5,319,018, 5,574,090,5,676,741 and 6,228,913, as well as subsequent patent documents citingthese. Examples of suitable polymer materials useful within latex(water-based) or solvent-based liquid media and that can form usefulfilms or coatings include, but are not limited to, polymers known asacrylate polymers, styrene-polydiene polymers, polypropylenes,polyacetals, polyamides, polyesters, polystyrenes, polyvinyl chlorides,polyvinylidene chlorides, polyurethanes, polyureas, and the like.

The non-volatile solids content of such floor care compositions can beat least ˜20%, ˜18%, ˜15%, or even as little as ˜5%, and can be up to˜25%, ˜30%, ˜35%, or even ˜40%. The non-volatile solids can include aminimum of ˜80%, ˜75%, or even ˜70% synthesized polymer; in these orother embodiments, synthesized polymer can constitute up to ˜85%, ˜90%,˜94%, ˜96%, ˜98%, or even ˜99% of the non-volatile solids. The dynamicviscosity of such compositions, when measured by a Brookfield viscometerusing a #1 spindle at 1 rotation per second, usually are less than ˜0.01Pa·s (10 cP).

The polymer of a polymer composition refers to a synthesized polymergenerally in the form of water insoluble particles dispersed, suspendedor otherwise entrained in a liquid. Commonly the polymer can be in theform of solid polymer particles dispersed or suspended within a liquidmedium such as a continuous aqueous phase; this form of a latex may beconsidered an emulsion, a dispersion, or the like. The dynamic viscosityof the polymer (e.g., in the form of a latex) when measured as describedabove is generally less than ˜0.25 Pa·s (250 cP). Polymer particlesoptionally can include compositionally distinct regions, e.g.,core-shell architecture, or can be substantially homogeneous. Average ormean diameters of polymer particles can typically be less than ˜140 nm,generally less than ˜100 nm, commonly less than ˜90 nm, and often lessthan ˜80 nm, although rarely less than ˜70 nm. (Particle size can begiven as an average determined by capillary hydrodynamic fractionation,a chromatographic method in which particles of varying sizes elute atdifferent times from a narrow-bore capillary column.) Particle sizedistribution generally is less than 2.0, commonly less than 1.5, morecommonly less than 1.1, and preferably on the order of ˜1.05. Polymerparticles can display essentially any gel content value, although commonvalues range from ˜50-90%. The polymer (solids) content of the latex cangenerally range from ˜30 to ˜55%, although higher amounts can beachieved in certain circumstances.

Useful polymers can have a glass transition temperature (T_(g)) of atleast 10° C., at least ˜20° C., at least ˜30° C., or at least ˜40° C.,and as high as 100° C., commonly ˜80° C., more commonly ˜70° C., andeven more commonly ˜60° C. The T_(g) of a given polymer may bedetermined by differential scanning calorimetry (DSC) tests performed ondried films made from the polymer or can be estimated from the Foxequation.

As mentioned previously, a variety of synthetic polymers can be used insuch compositions. A significant number of these are commonly referredto as acrylic polymers because of their inclusion of mer derived from(meth)acrylic acid or alkyl esters thereof. These polymers generallyinclude

-   -   up to 70%, commonly ˜10 to ˜50%, vinyl aromatic mer such as can        result from inclusion of at least one of styrene, any of a        variety of halogenated styrenic monomers, vinyl toluene, o- or        p-methoxy styrene, allyl phenyl ether, allyl tolyl ether and        α-methyl styrene;    -   from ˜3 to ˜50%, commonly ˜5 to 20%, acidic mer such as can        result from inclusion of at least one of maleic acid, fumaric        acid, cinnamic acid, aconitic acid, crotonic acid, citraconic        acid, acryloxypropionic acid, (meth)acrylic acid, itaconic acid,        and partial esters of those of the foregoing which are        poly-acids;    -   from ˜30 to ˜97%, commonly ˜35 to ˜70%, mer derived from C₁-C₂₀,        preferably C₁-C₁₂, alkyl(meth)acrylates such as        methyl(meth)acrylate, ethyl(meth)acrylate,        n-butyl(meth)acrylate, isobutyl(meth)acrylate, 2-ethyl hexyl        acrylate, n-octyl acrylate, sec-butyl acrylate, cyclopropyl        meth-acrylate, acetoacetoxyethyl(meth)acrylate,        acetoacetoxypropyl(meth)-acrylate,        acetoacetoxybutyl(meth)acrylate,        2,3-di(acetoacetoxy)propyl(meth)acrylate, and the like;    -   optionally up to 40% mer derived from at least one polar or        polarizable non-ionogenic hydrophilic monomer, such as        (meth)acrylonitrile, crotononitrile, α-cyanostyrene,        α-chloroacrylonitrile, ethyl vinyl ether, isopropyl vinyl ether,        isobutyl- and butyl-vinyl ether, diethylene glycol vinyl ether,        decyl vinyl ether, vinyl acetate, isobornyl methacrylate,        hydroxyalkyl(meth)acrylate such as 2-hydroxyethyl(meth)acrylate,        2- or 3-hydroxy-propyl(meth)acrylate, butanediol acrylate, and        3-chloro-2-hydroxypropyl acrylate, as well as vinyl thiols such        as 2-mercaptopropyl methacrylate, 2-sulfoethyl methacrylate,        methyl vinyl thiol ether and propyl vinyl thio ether; and    -   optionally up to 10% mer derived from at least one monomeric        vinyl ester in which the acid moiety of the ester results from        aromatic C₁-C₁₈ aliphatic acids such as formic, acetic,        propionic, n-butyric, n-valeric, palmitic, stearic, phenyl        acetic, benzoic, chloroacetic, dichloroacetic, γ-chloro butyric,        4-chlorobenzoic, 2,5-dimethyl benzoic, o-toluic,        2,4,5-trimethoxy benzoic, cyclobutane carboxylic, cyclohexane        carboxylic, 1-(p-methoxy phenyl)cyclohexane carboxylic,        1-(p-tolyl)-1-cyclopentane carboxylic, hexanoic, myristic, and        p-toluic acids.        (The relative amounts of mer may be approximated by the amounts        of respective monomers used when the polymerization techniques        and conditions permit substantially complete conversion.)

Also useful are styrene-polydiene interpolymers such as those in intl.publ. no. WO 2008/011020. In addition to the types of mer included inthe polymers described immediately above, styrene-polydieneinterpolymers can include from ˜5 to ˜50%, commonly from ˜10 to ˜40%,and more commonly from ˜20 to ˜35% polyene mer, typically resulting frominclusion of conjugated polyene mer such as 1,3-butadiene, isoprene,1,3-pentadiene, 1,3-hexadiene, 2,3-dimethyl-1,3-butadiene,2-ethyl-1,3-butadiene, 2-methyl-1,3-pentadiene, 3-methyl-1,3-pentadiene,4-methyl-1,3-pentadiene, 2,4-hexadiene, and the like. Astyrene-polydiene interpolymer can also can include relatively higheramounts of vinyl aromatic mer, e.g., up to ˜75% or even 80%. When theseinterpolymers include acidic mer, which can result from inclusion ofversatic acid in addition to the acidic monomers described above, floorcare compositions incorporating the polymer can exhibit good durability,black heel mark resistance, and good water resistance. Theseinterpolymers also can include up to ˜10% mer derived from functionalmonomers that help to control the hydrophilic/hydrophobic properties ofthe polymer, improve the compatibility of the polymer with one or moreadditives, and/or affect hydrogen bonding with acid functionality in thepolymer; examples of such functional monomers include2-hydroxyethyl(meth)acrylate, n-methylol (meth)acryl-amide,(meth)acrylamide, and the like.

Polymers of the foregoing types can be prepared by emulsionpolymerization techniques such as those generally described in U.S. Pat.Nos. 3,573,239, 3,328,325, 3,554,790, 3,467,610, 5,166,259, and6,425,978. These types of polymerization processes use up to ˜5% of oneor more surfactants which, for present purposes, are referred to asinternal surfactants; examples of potentially useful internalsurfactants include one or more of the following: salts of alkylsulfosuccinates such as sodium dihexyl sulfosuccinate and sodium dioctylsulfosuccinate; salts of alkyl sulfates such as sodium lauryl sulfate;salts of organo disulfonates such as dodecyl diphenyloxide disulfonate;sodium laureth sulfate; sodium lauryl ether sulfate; sodium laureth-12sulfate; sodium laureth-30 sulfate; sodium dodecyl benzene sulfonate;and organophosphates such as those described in published patent appl.no. US 2005/0215678 A1. If desired, the emulsion polymerization mixturecan include a plasticizer and/or coalescing agent, the inclusion ofwhich can lower film formation temperature of the latex composition byup to 10° -20° C. The emulsion polymerization mixture also can include,based on the total weight of monomers, up to ˜2% of an internalcrosslinking agent such as divinylbenzene and any of a variety offunctional di- and tri-(meth)acrylates and/or up to ˜3% of a chaintransfer agent.

Finish compositions such as paints and floor care compositions, amongother types, are complex mixtures that, in addition to polymer latex,employ a wide variety of components in widely varying amounts and types.Many known and useful materials can be mixed into a polymer composition(e.g., latex) after preparation of the polymer and before transportwithout deleteriously affecting storage stability or other properties;alternatively, many of the same and/or other materials can be mixed witha latex subsequent to manufacture and transport. A variety of importanttypes of added ingredients (especially for floor care compositions) thatcan be present in these compositions are discussed below. In addition tothose, however, other additional components can include externalsurfactants, preservatives, defoamers, biocides, fragrances, dyestuffs,brighteners, antioxidants, and UV absorbing agents, among still others.

One commonly used added ingredient is an external crosslinking agent,which facilitates the linking of polymer particles or chains, typicallythrough acid functionalities. Where a bifunctional external crosslinkingagent is included, the agent can react or interact with acidfunctionalities on two chains, thereby linking those chains andimproving certain characteristics of a coating that results from thefinish composition. Salts or complexes of polyvalent metals (e.g., Ca,Mg, Zn, Ba, Al, Zr, Ni, Fe, Cd, Sr, Bi, Be, Co, Pb, Cu, Ti, Sb, etc.)often are used as external crosslinking agents, as is aziridine; some ofthe most commonly used complexes include zinc ammonium carbonate, zincammonium acetate, zinc ammonium acrylate, zinc ammonium maleate, zincammonium aminoacetate, calcium ammonium alanine, calciumethylenediamine-ammonium carbonate, zirconium ammonium carbonate andzirconium ammonium maleate. The amount of external crosslinking agentincluded in a finish composition can be calculated on the equivalents ofacid groups within a polymer chain of a polymer of the composition.Examples of useful amounts of external crosslinking agent can be from˜0.25 to ˜0.5 mole crosslinking agent per equivalent of acid group in apolymer. Although not required, external crosslinking agent can be addedto the polymerization medium after formation of latex but prior toformation of a finish composition (e.g., aqueous floor carecomposition), i.e., added to the latex composition prior to storage orshipment.

In certain preferred embodiments of floor care compositions, an externalcrosslinking agent can be zinc as opposed to other useful metalcrosslinking agents. Zinc (e.g., ZnO) can be present in a floor carecomposition in an amount per acid functionality (of the polymer) of from0.05 mole ZnO to 0.5 mole ZnO, per mole of acid functionality (—COOH) inthe polymer.

In other floor care composition embodiments, the use of heavy metalssuch as zinc can be reduced or eliminated. In such compositions, amountsof zinc as a heavy metal external crosslinking agent (e.g., ZnO), orother heavy metal external crosslinking agent, can be kept to a levelbelow about 0.05 mole heavy metal crosslinking agent per equivalent acidfunctionality (—COOH) in the polymer, preferably below about 0.01 moleheavy metal crosslinking agent per equivalent of acid functionality inthe polymer.

Another commonly used added ingredient in a finish composition (e.g.,floor care composition) is wax, which can affect sliding properties,durability, and black heel mark resistance of a floor coating providedfrom the composition. Examples of natural waxes include carnauba,paraffin, and the like, while examples of synthetic waxes include any ofa variety of poly(alkylene)s and oxides thereof. Floor care compositionsoften contain wax, based on the total weight of nonvolatile components(solids) in a floor care composition, in amounts up to ˜55 weightpercent wax, commonly from ˜1 to ˜30 weight percent, and typically from˜5 to ˜20 weight percent.

Another added ingredient that may be useful in finish composition suchas a floor care composition is an alkali-soluble resin, which can affectthe leveling properties of a composition. Examples of alkali-solubleresins include styrene-acrylic acid interpolymers, styrene-maleic acidinterpolymers, rosin-maleic acid copolymer resins, water-soluble acrylicresins, water-soluble polyester resins, and water-soluble epoxy resins.Useful amounts of alkali-soluble resins based on total weight finishcomposition can be amounts up to ˜50% alkali-soluble resin by weight,commonly from ˜1 to ˜20%, and typically from ˜3 to ˜10%.

Another added ingredient that may be useful in a finish composition suchas a floor care composition is an aqueous polyurethane resin. An aqueouspolyurethane resin can affect durability of a dried coating providedfrom the composition. Examples of aqueous polyurethane resins includepolyurethanes that include a bonded carboxylic acid or carboxylategroup. Polyurethane-type resins can be included in a finish composition,based on total weight of finish composition, can be up to ˜80 weightpercent aqueous polyurethane-type resins, commonly from ˜1 to ˜60%, andtypically from ˜20 to ˜40%. (Thus, polyurethane can be an additionalingredient in the provision a floor care composition. This is inaddition to the teaching elsewhere herein that a polymer compositionalso or alternatively can include polyurethane as one of its constituentpolymers.)

Still another added ingredient that may be useful in a finishcomposition such as a floor care composition can be a plasticizer, whichcan be an ingredient that functions to reduce the minimum film-formingtemperature of the composition. Exemplary plasticizers include dialkylphthalates, 2-pyrrolidone, octyl diphenyl phosphate, esters of benzoicacid, and tributoxyethyl phosphate. Useful amounts of plasticizer in afinish composition, based on total weight finish composition, can beamounts up to ˜5 weight percent, commonly from ˜1 to ˜4%, and typicallyfrom ˜2 to ˜3%.

Still another potentially useful added ingredient, particularly in floorcare compositions, is a coalescent, which can assist in formingcontinuous films where the composition is applied at elevatedtemperatures. Exemplary coalescents include alcohols such as ethanol,isopropyl alcohol, etc., as well as polyols and glycol ethers. Usefulamounts of coalescent based on total weight of a finish composition canbe amounts up to ˜10 weight percent coalescent, commonly from ˜1 to ˜7%,and typically from ˜3 to ˜5%.

An important component included in many floor care compositions is aleveling agent or aid. Many commercial floor care compositions includepolyfluorooxetanes (see, e.g., U.S. Pat. Nos. 6,660,828 and 7,022,801),non-ionic surfactants, anionic surfactants, silicone-based surfactants,or fluorine-containing surfactants (e.g., Zonyl™ fluorosurfactants;DuPont, Wilmington, Del.) as leveling aids. When used, preferred amountsof leveling agent such as a fluorosurfactant (e.g., PolyFox™ PF-2002,OMNOVA Solutions, Akron, Ohio) can be present in a finish composition atany useful level, such as within the range from 50 to 200 ppm.

Exemplary compositions of the present description can include usefulamounts of polymer and metal salt of a fatty acid (of a polymercomposition) combined with added ingredients to produce a useful finishcomposition such as a floor care composition. Added ingredients combinedwith polymer composition to produce a floor care composition may includeany one or more of surfactant, which may be any of various known typesincluding anionic, ionic, nonionic, etc.; plasticizer; wax; defoamer;preservatives; and other ingredients.

In a non-limiting sense, certain ingredients may be useful in apolymeric floor care (finish) composition in amounts such as thefollowing: from 10 to 45 or 12 to 40 pbw polymer solids (preferablysuspended or dissolved in a continuous aqueous phase); from 0.5 to 10 or2 to 6 pbw metal salt of a fatty acid, e.g., calcium stearate; up to 5or from 0.5 to 2.5 pbw wax; and up to 10 or from 1 to 5 pbw plasticizer.

Other finish composition such as paints, protective wood finishes, etc.,can be prepared using ingredients and amounts of ingredients that arecommon or well-known and useful for those functional coatings, such asby use of pigment for paints.

A polymer composition as described herein, including polymer and a metalsalt of a fatty acid, can be prepared by providing or preparing apolymer, e.g., by any presently known method or any method that isdeveloped in the future. Methods include known or useful latexpolymerization methods. The prepared or otherwise provided polymer canbe combined with the metal salt of a fatty acid, preferably after thepolymer is prepared. In preferred embodiments the polymer is prepared asor provided in the form of a water-based latex (e.g., dispersion,suspension, or the like) comprising polymer particles suspended in acontinuous aqueous phase. The polymer latex can be blended with metalsalt of a fatty acid (e.g., calcium stearate). The metal salt of a fattyacid can be added to the synthesized polymer in a subsequent blendingstep, in a desired amount. A polymer composition prepared in thismanner, described herein as containing solids that consist of or consistessentially of polymer and metal salt of a fatty acid, can be shipped,stored, used, or processed as desired.

The polymer composition can be used to prepare a finish composition asdesired, by combining the polymer composition with added ingredients toform, e.g., a paint, wax, polish, wood finish, or floor carecomposition. The order of addition of ingredients to prepare the finishcomposition typically is not particularly important. One or more of theadded ingredients, optionally dissolved or suspended in water, can (ifdesired or useful) be mixed with the polymer composition (preferably inthe form of a latex) prior to shipment of the polymer composition to alocation at which the finish composition is to be prepared.

One particularly desirable property of a polymer composition or a finishcomposition is stability. Emulsions are considered stable if they do notseparate over a determined amount of time, such as over 30 days whenstored at elevated temperature (between 125° to 150° F.).

A finish composition can be used as desired, e.g., to coat a vertical orhorizontal surface. For example, a floor care composition can be used asa polishing or protective agent for floors, as well as other substratessuch as furniture, vehicles, building materials (e.g., windows), and thelike. A floor care composition can be used to provide coatings to floorsmade of wood, wooden materials, synthetic resins, concrete, marble,stone and the like.

A floor can be coated, and thereby protected, by applying a floor carecomposition to a floor substrate and allowing the coating to dry atambient or elevated temperature; application of the floor carecomposition can be by fabric coating, brush spraying, brushing, etc.,advantageously, at or about room temperature. Such coated floors canexhibit advantageous water resistance, scratch resistance, a desireddegree of gloss (e.g., from semi-gloss to matte finish), and glossretention. Additionally or optionally, the coated floor does not exhibityellowing.

A floor care composition can be used to prepare a coated floor that hasa coating (i.e., film) thickness of up to ˜70 μm, commonly from ˜5 to˜50 μm, and typically from ˜10 to ˜30 μm. Film thickness can bedeveloped over several applications.

Coatings of the invention (floor care coatings, paint coatings, orotherwise) can be characterized by the described use of a metal salt ofa fatty acid (e.g., calcium stearate) to control degree of gloss of adried coating. For example, a dried coating may have a gloss valuemeasured at 60° (using a procedure such as that set forth in ASTMD-1455-87, employing 3 coats at an application weight of 2 mL/ft²(0.0929 mL/m²) on a standard vinyl tile) of below 65, such as below 50,below 40, below 30, below 20, or below 10.

An exemplary finish (floor care) composition is provided below. Theas-recited formulation does not include any metal salt of fatty acid,but a desired amount of a metal salt of fatty acid (e.g., calciumstearate) can be added to reduce the gloss of the recited finishcomposition. (All values are weight percentages, with the total summingto 100%.)

A water 47.22 diethylene glycol monoethyl ether 4.05 tributoxyethylphosphate 2.70 PolyFox ™ TM-1 fluorosurfactant (OMNOVA 0.05 Solutions)defoamer 0.01 preservative 0.05 B Mor-Glo ™ 2 polyacrylate emulsion, 38%solids 39.47 (OMNOVA Solutions) Conrez ™ alkali-soluble resin, 30%solids (OMNOVA 1.00 Solutions) C AC-325 nonionic wax emulsion 3.57Epolene ™ E-43 nonionic wax emulsion 1.88The A ingredients are mixed for 5-10 minutes before addition of the Bingredients. After another 5-10 minutes of additional mixing, the waxes(C ingredients) are added followed by ˜30 minutes of mixing. The totalsolids content of this composition is 20 weight percent.

Provided below are exemplary floor care composition formulations (withall values being weight percents), each having 25% total solids (byweight).

1 2 water 40.13 37.53 diethylene glycol ethyl ether 2.23 2.80tributoxyethyl phosphate 2.68 3.36 PolyFox ™ PF-2002 fluorosurfactant(OMNOVA 0.05 0.05 Solutions) NM ™ 128 latex, 38% solids (OMNOVASolutions) 39.13 Sunkote ™ 459 calcium stearate, 50% solids 9.00 (OMNOVASolutions) 5:95 (wt.) blend, Sunkote ™ 459 & NM ™ 128, 39% 50.55 solidsEpolene ™ E-43 nonionic wax emulsion 2.50 AC-325 nonionic wax emulsion4.29 5.71

1. A composition comprising, in a liquid medium, from 0.5 to 10 parts by weight metal salt of a fatty acid, from 10 to 45 parts by weight of one or more polymers, up to 5 parts by weight wax, and up to 10 parts by weight plasticizer.
 2. The composition of claim 1 comprising from 30 to 60 weight percent solids, said liquid comprising water and said composition being free of wax and plasticizer.
 3. The composition of claim 1 comprising from 0.5 to 2.5 parts by weight wax and from 1 to 5 parts by weight plasticizer.
 4. The composition of claim 3 comprising from 5 to 40 weight percent solids, said liquid comprising water.
 5. The composition of claim 4 further comprising at least one fluorosurfactant.
 6. The composition of claim 1 any of claims 1 wherein said fatty acid is stearic acid.
 7. The finish composition of claim 6 wherein said metal salt of a fatty acid is calcium stearate.
 8. The composition of claim 1 wherein at least one of said one or more polymers comprises styrene and acrylate mer.
 9. The composition of claim 1 wherein at least one of said one or more polymers comprises styrene and polyene mer.
 10. A coated floor comprising a substrate bearing on a primary show surface a coating that comprises a dried composition according to claim
 3. 11. A composition according to claim 1 any of claims 1 comprising from 2 to 6 parts by weight metal salt of a fatty acid, from 12 to 40 parts by weight polymer selected from the group consisting of acrylic polymer and styrene-polydiene polymer, and from 30 to 60 weight percent solids in an aqueous medium.
 12. A composition according to claim 1 any of claims 1 wherein the fatty acid comprises a linear, saturated alkyl chain having from 15 to 25 carbon atoms.
 13. A composition according to claim 9 comprising below about 0.05 mole heavy metal crosslinking agent per mole equivalent acid functionality (—COOH) in the polymer.
 14. A method of providing a polymer finish composition, the method comprising providing a polymer composition as recited at claim 1, and combining the polymer composition with added ingredient to produce a polymer finish composition.
 15. A coated floor according to claim 10 wherein the dried composition exhibits a gloss reading of below 50 when measured according to ASTM D-1455-87. 